Multi-step and asymmetrically shaped laser beam scribing

ABSTRACT

Methods of dicing substrates by both laser scribing and plasma etching. A method includes laser ablating material layers, the ablating leading with a first irradiance and following with a second irradiance, lower than the first. Multiple passes of a beam adjusted to have different fluence level or multiple laser beams having various fluence levels may be utilized to ablate mask and IC layers to expose a substrate with the first fluence level and then clean off redeposited materials from the trench bottom with the second fluence level. A laser scribe apparatus employing a beam splitter may provide first and second beams of different fluence from a single laser.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part (CIP) of U.S. patent application Ser. No. 13/160,822, entitled “Multi-step and Asymmetrically Shaped Laser Beam Scribing,” and filed on Jun. 15, 2011, the entire contents of which are hereby incorporated by reference in its entirety for all purposes.

TECHNICAL FIELD

Embodiments of the present invention pertain to the field of semiconductor processing and, in particular, to methods for dicing substrates, each substrate having an integrated circuit (IC) thereon.

BACKGROUND DESCRIPTION OF RELATED ART

In semiconductor substrate processing, ICs are formed on a substrate (also referred to as a wafer), typically composed of silicon or other semiconductor material. In general, thin film layers of various materials which are either semiconducting, conducting or insulating are utilized to form the ICs. These materials are doped, deposited and etched using various well-known processes to simultaneously form a plurality of ICs, such as memory devices, logic devices, photovoltaic devices, etc, in parallel on a same substrate.

Following device formation, the substrate is mounted on a supporting member such as an adhesive film stretched across a film frame and the substrate is “diced” to separate each individual device or “die” from one another for packaging, etc. Currently, the two most popular dicing techniques are scribing and sawing. For scribing, a diamond tipped scribe is moved across a substrate surface along pre-formed scribe lines. Upon the application of pressure, such as with a roller, the substrate separates along the scribe lines. For sawing, a diamond tipped saw cuts the substrate along the streets. For thin substrate singulation, such as <150 μms (μm) thick bulk silicon singulation, the conventional approaches have yielded only poor process quality. Some of the challenges that may be faced when singulating die from thin substrates may include microcrack formation or delamination between different layers, chipping of inorganic dielectric layers, retention of strict kerf width control, or precise ablation depth control.

While plasma dicing has also been contemplated, a standard lithography operation for patterning resist may render implementation cost prohibitive. Another limitation possibly hampering implementation of plasma dicing is that plasma processing of commonly encountered interconnect metals (e.g., copper) in dicing along streets can create production issues or throughput limits. Finally, masking of the plasma dicing process may be problematic, depending on, inter alia, the thickness and top surface topography of the substrate, the selectivity of the plasma etch, and the materials present on the top surface of the substrate.

SUMMARY

Embodiments of the present invention include methods of laser scribing substrates. In the exemplary embodiment, the laser scribing is implemented as a first operation in a hybrid dicing process including both laser scribing and plasma etching.

In an embodiment, a method of dicing a semiconductor substrate having a plurality of ICs includes receiving a masked semiconductor substrate, the mask covering and protecting ICs on the substrate. The masked substrate is ablated along streets between the ICs with a point on the substrate exposed to increasing irradiance. In one embodiment, at least a portion of the mask thickness in the street is ablated through exposure to electromagnetic radiation of first irradiance (optical intensity) to provide a patterned mask with gaps or trenches. At least a portion of a thin film device layer stack disposed below the mask is then ablated through exposure to electromagnetic radiation having second irradiance to expose regions of the substrate between the ICs. The ICs are then singulated into chips, for example by plasma etching through the exposed substrate following the trenches in the patterned mask.

In another embodiment, a system for dicing a semiconductor substrate includes a laser scribe module and a plasma etch chamber, integrated onto a same platform. The laser scribe module is to iteratively scribe the substrate and the plasma chamber is to etch through the substrate and singulate the IC chips. The laser scribe module may include one or more of a multiple lasers, a multi-pass controller, or a beam shaper to scribe the substrate via exposure to a plurality of optical intensities.

In another embodiment, a method of dicing a substrate having a plurality of ICs includes receiving a masked silicon substrate. The ICs include a copper bumped top surface having bumps surrounded by a passivation layer, such as polyimide (PI). Subsurface thin films below the bumps and passivation include a low-K interlayer dielectric (ILD) layer and a layer of copper interconnect, the entire set of layers comprising a device film layer stack. A femtosecond laser ablates, through irradiation, a predetermined pattern of trenches into the film layer stack by one or more sequential laser irradiation steps and into a thin film IC stack disposed below the mask with a second irradiance to expose a portion of a substrate and may further ablate into the same substrate such that there is sufficiently small amounts of residual film layer stack remaining on the substrate at the trench bottoms. The ablation leads with a first irradiance and follows with a second irradiance greater than, less than, or essentially equal to the first irradiance. The kerf width may additionally be reduced or increased with changing irradiance. A plasma etch is performed in a plasma etch chamber to additionally remove substrate material below the removed film layer stack to singulate individual ICs out of the single substrate. Any remaining mask material is then removed by a suitable method such as washing by solvent or dry plasma cleaning.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention are illustrated by way of example, and not limitation, in the figures of the accompanying drawings in which:

FIG. 1 is a flow diagram illustrating a hybrid laser ablation-plasma etch singulation method with a laser scribing process leading with a first irradiance and following with a second irradiance, in accordance with an embodiment of the present invention;

FIG. 2A is a flow diagram illustrating a laser scribing process which may be utilized in FIG. 1, in accordance with an embodiment of the present invention;

FIG. 2B is a flow diagram illustrating a laser scribing process which may be utilized in FIG. 1, in accordance with an embodiment of the present invention;

FIG. 2C is a flow diagram illustrating a laser scribing process which may be utilized in FIG. 1, in accordance with an embodiment of the present invention;

FIG. 3A is a graph of irradiance over time for a laser scribing process, in accordance with an embodiment of the present invention;

FIG. 3B is a graph of a spatial profile of an asymmetric laser beam for a single-pass laser scribing process, in accordance with an embodiment of the present invention;

FIG. 3C is a graph of a spatial profiles of laser beams for a multi-pass laser scribing process, in accordance with an embodiment of the present invention;

FIG. 4A illustrates a cross-sectional view of a substrate including a plurality of ICs corresponding to operation 101 of the dicing method illustrated in FIG. 1, in accordance with an embodiment of the present invention;

FIG. 4B illustrates a cross-sectional view of a substrate including a plurality of ICs corresponding to operation 103 of the dicing method illustrated in FIG. 1, in accordance with an embodiment of the present invention;

FIG. 4C illustrates a cross-sectional view of a substrate including a plurality of ICs corresponding to operation 104 of the dicing method illustrated in FIG. 1, in accordance with an embodiment of the present invention;

FIG. 4D illustrates a cross-sectional view of a semiconductor substrate including a plurality of ICs corresponding to operation 105 of the dicing method illustrated in FIG. 1, in accordance with an embodiment of the present invention;

FIG. 5 illustrates an expanded cross-sectional view of an mask and thin film device layer stack ablated by a laser and plasma etched, in accordance with embodiments of the present invention;

FIG. 6A illustrates a block diagram of an integrated platform layout for laser and plasma dicing of substrates, in accordance with an embodiment of the present invention; and

FIG. 6B illustrates a block diagram of a laser scribing module for laser scribing, in accordance with an embodiment of the present invention;

FIG. 7 illustrates a block diagram of an exemplary computer system which controls automated performance of one or more operation in the laser scribing methods described herein, in accordance with an embodiment of the present invention;

FIG. 8A is a flow diagram illustrating a hybrid laser ablation-plasma etch singulation method with a laser scribing process leading with a first irradiance and following with a second irradiance lower than the first irradiance, in accordance with an embodiment of the present invention;

FIGS. 8B, 8C, and 8D illustrate cross-sectional views of a substrate corresponding to operations of the dicing method illustrated in FIG. 8A, in accordance with an embodiment of the present invention

FIG. 9A is a flow diagram illustrating a hybrid laser ablation-plasma etch singulation method with a split beam laser scribing process leading with a first irradiance and following with a second irradiance, in accordance with an embodiment of the present invention;

FIG. 9B illustrates a schematic diagram of a laser scribing module for split beam laser scribing, in accordance with an embodiment of the present invention; and

FIG. 10 illustrates a schematic of a beam-splitter, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

Methods of dicing substrates, each substrate having a plurality of ICs thereon, are described. In the following description, numerous specific details are set forth, such as femtosecond laser scribing and deep silicon plasma etching conditions in order to describe exemplary embodiments of the present invention. However, it will be apparent to one skilled in the art that embodiments of the present invention may be practiced without these specific details. In other instances, well-known aspects, such as IC fabrication, substrate thinning, taping, etc., are not described in detail to avoid unnecessarily obscuring embodiments of the present invention. Reference throughout this specification to “an embodiment” means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments. Also, it is to be understood that the various exemplary embodiments shown in the Figures are merely illustrative representations and are not necessarily drawn to scale.

The terms “coupled” and “connected,” along with their derivatives, may be used herein to describe structural relationships between components. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” my be used to indicate that two or more elements are in either direct or indirect (with other intervening elements between them) physical or electrical contact with each other, and/or that the two or more elements co-operate or interact with each other (e.g., as in a cause an effect relationship).

The terms “over,” “under,” “between,” and “on” as used herein refer to a relative position of one material layer with respect to other material layers. As such, for example, one layer disposed over or under another layer may be directly in contact with the other layer or may have one or more intervening layers. Moreover, one layer disposed between two layers may be directly in contact with the two layers or may have one or more intervening layers. In contrast, a first layer “on” a second layer is in contact with that second layer. Additionally, the relative position of one layer with respect to other layers is provided assuming operations are performed relative to a substrate without consideration of the absolute orientation of the substrate.

Generally, described herein is a laser scribe process employing a plurality of optical intensities to cleanly ablate a predetermined path through an unpatterned (i.e., blanket) mask layer, a passivation layer, and subsurface thin film device layers. The laser scribe process may then be terminated upon exposure of, or partial ablation of, the substrate. The ablation processing employs first of a plurality of optical intensities to remove upper layers (e.g., mask and thin film device layers) which are more easily damaged relative to the substrate and/or other thin film device layers. Subsequent ablation down to and including a portion of the substrate may then proceed without exposing the easily damaged layers to the higher intensity radiation employed. As employed herein the term “iterative ablation” refers to an ablation process which exposes a point on a substrate to laser radiation having a plurality of optical intensities.

In accordance with an embodiment of the present invention, at least a portion of the iterative laser scribing process employs a femtosecond laser. Femtosecond laser scribing is an essentially, if not completely, non-equilibrium process. For example, the femtosecond-based laser scribing may be localized with a negligible thermal damage zone. In an embodiment, femtosecond laser scribing is used to singulate ICs having ultra-low κ films (i.e., with a dielectric constant below 3.0). In one embodiment, direct writing with a laser eliminates a lithography patterning operation, allowing the masking material to be something other than a photo resist as is used in photolithography. In the exemplary hybrid dicing embodiment, an iterative laser scribing process is followed by a plasma etch through the bulk of the substrate. In one such embodiment, a substantially anisotropic etching is used to complete the dicing process in a plasma etch chamber; the anisotropic etch achieving a high directionality into the substrate by depositing on sidewalls of the etched trench an etch polymer.

FIG. 1 is a flow diagram illustrating a hybrid laser ablation-plasma etch singulation method 100 employing iterative laser scribing, in accordance with an embodiment of the present invention. FIGS. 4A-4D illustrate cross-sectional views of a substrate 406 including first and second ICs 425, 426 corresponding to the operations in method 100, in accordance with an embodiment of the present invention.

Referring to operation 101 of FIG. 1, and corresponding FIG. 4A, a substrate 406 is received. The substrate 406 includes a mask 402 covering a thin film device layer stack 401 comprising a plurality of distinct materials found both in the ICs 425, 426 and intervening street 427 between the ICs 425, 426. Generally, the substrate 406 is composed of a material suitable to withstand a fabrication process of the thin film device layers formed thereon and may also have other property requirements, for example, in silicon-based transistor ICs, where the substrate forms a part of active devices. For example, in one embodiment, substrate 406 is a group IV-based material such as, but not limited to, monocrystalline silicon, germanium or silicon/germanium. In another embodiment, substrate 406 is a III-V material such as, e.g., a III-V material substrate used in the fabrication of light emitting diodes (LEDs). During device fabrication, the substrate 406 is typically 600 μm-800 μm thick, but as illustrated in FIG. 4A may have been thinned to less than 400 μm and sometimes thinner than 150 um with the thinned substrate now supported by a carrier 411, such as a backing tape 410 stretched across a support structure of a dicing frame (not illustrated) and adhered to a backside of the substrate with a die attach film (DAF) 408.

In embodiments, first and second ICs 425, 426 include memory devices or complimentary metal-oxide-semiconductor (CMOS) transistors fabricated in a silicon substrate 406 and encased in a dielectric stack. A plurality of metal interconnects may be formed above the devices or transistors, and in surrounding dielectric layers, and may be used to electrically couple the devices or transistors to form the ICs 425, 426. Materials making up the street 427 may be similar to or the same as those materials used to form the ICs 425, 426. For example, street 427 may include thin film layers of dielectric materials, semiconductor materials, and metallization. In one embodiment, the street 427 includes a test device similar to the ICs 425, 426. The width of the street 427 may be anywhere between 10 μm and 200 μm, measured at the thin film device layer stack/substrate interface.

In embodiments, the mask 402 may be one or more material layers including any of a plasma deposited polymer (e.g., C_(x)F_(y)), a water soluble material (e.g., poly(vinyl alcohol)), a photoresist, or similar polymeric material which may be removed without damage to an underlying passivation layer, which is often polyimide (PI) and/or bumps, which are often copper. The mask 402 is to be of sufficient thickness to survive a plasma etch process (though it may be very nearly consumed) and thereby protect the copper bumps which may be damaged, oxidized, or otherwise contaminated if exposed to the substrate etching plasma.

FIG. 5 illustrates an expanded cross-sectional view 500 of a bi-layer mask including a mask layer 402B (e.g., C_(x)F_(y) polymer) applied over a mask layer 402A (e.g., a water soluble material) in contact with a top surface of the IC 426 and the street 427, in accordance with embodiments of the present invention. As shown in FIG. 5, the substrate 406 has a top surface 503 upon which thin film device layers are disposed which is opposite a bottom surface 502 which interfaces with the DAF 408 (FIG. 4A). Generally, the thin film device layer materials may include, but are not limited to, organic materials (e.g., polymers), metals, or inorganic dielectrics such as silicon dioxide and silicon nitride. The exemplary thin film device layers illustrated in FIG. 5 include a silicon dioxide layer 504, a silicon nitride layer 505, copper interconnect layers 508 with low-κ (e.g., less than 3.5) or ultra low-κ (e.g., less than 3.0) interlayer dielectric layers 507 (ILD) such as carbon doped oxide (CDO) disposed there between. A top surface of the IC 426 includes a bump 512, typically copper, surrounded by a passivation layer 511, typically a polyimide (PI) or similar polymer. The bump 512 and passivation layer 511 therefore make up a top surface of the IC with the thin film device layers forming subsurface IC layers. The bump 512 extends from a top surface of the passivation layer 511 by a bump height H_(B) which in the exemplary embodiments ranges between 10 μm and 50 μm. One or more layers of the mask may not completely cover a top surface of the bump 512.

Referring back to FIG. 1, at operation 103 a predetermined pattern is directly written into the mask 402 with a first ablation along a controlled path relative to the substrate 406. As illustrated in corresponding FIG. 4B, the mask 402 is patterned in the first ablation by laser radiation 411 to form trench 414A extending through at least a portion of the mask thickness. In the exemplary embodiment illustrated in FIG. 5, the laser scribing depth D_(L1) is approximately in the range of 5 μm to 30 μm deep, advantageously in the range of 10 μm to 20 μm deep, depending on the thickness of the mask layers 402A and 402B. The first irradiance I₁ is insufficient to ablate some layer of the thin film device layer stack 401 and therefore at least some portion of the thin film device layer stack 401 remains at the bottom of the trench 414A following operation 103. In one such embodiment, the first irradiance I₁ is insufficient to ablate an interconnect metal (e.g., interconnect copper layer 508) and/or a dielectric layer (e.g., silicon dioxide layer 504) of the thin film device layer stack 401.

At operation 104, the predetermined pattern is directly written with a second ablation iteration along the controlled path relative to the substrate 406. Referring to the exemplary embodiment in FIG. 4C, the substrate 406 is exposed to the second ablation iteration by laser radiation 412 forming trench 414B extending through at least a portion of the thin film device layer stack 401. In a first embodiment, as illustrated in FIG. 5, the laser scribing depth D_(L2) is again approximately in the range of 5 μm to 30 μm deep, advantageously in the range of 10 μm to 20 μm deep, depending on the thickness of the mask layers 402A and 402B to expose the substrate.

Depending on the embodiment the laser radiation 412 (FIG. 4C) has a second irradiance I₂ that is either same or different than the first irradiance I₁. In embodiments where the irradiance I₂ is the same as I₁, successive scribing allows for total energy applied to be spread over time to reduce damage of the scribing process. For certain such embodiments, kerf width may be different between I₁ and I₂ for further improvement in cleanliness of the ablated edge. In a first embodiment where the irradiance I₂ is different than I₁, the irradiance I₂ is greater than I₁, for example with the second irradiance I₂ sufficient to ablate an interconnect metal and/or a dielectric layer of the thin film device layer stack 401. In the exemplary embodiment, the second irradiance I₂ is sufficient to ablate every layer of the thin film device layer stack 401 and therefore operation 103 leaves the substrate 406 exposed at the bottom of the trench 414B. In a further embodiment, the second irradiance is sufficient to ablate a portion of the substrate 406, (e.g., single crystalline silicon) to extend the bottom of the trench 414B below the top surface of the substrate 406.

As further illustrated in FIGS. 4B 4C, the trench 414A has a first kerf width (KW₁) which is a function of a beam width possessing an energy greater than a threshold associated for the particular material of the mask 402 and the trench 414B has a second kerf width KW₂ as function of a beam width possessing an energy greater than a greatest threshold associated for the materials in the thin film device layer stack 401. In a first embodiment, the first kerf width KW₁ is larger than the second kerf width KW₂ so the mask 402 and upper layers of the thin film device stack 401 ablated at the first irradiance I₁ are not further disturbed by ablation of the underlying material layers ablated at the higher irradiance I₂. Notably in the exemplary embodiment, the entire first kerf width KW₁ is ablated to substantially the same depth as no point within the beam profile defining the kerf width KW₁ (perpendicular to direction of travel) has sufficient irradiance to ablate the entire thickness of the device stack. This is in contrast to a beam having a Gaussian spatial profile having a first irradiance at an outer perimeter of the beam diameter and a second irradiance within an inner diameter of the beam so that as the beam travels the leading edge of the beam makes a first kerf width KW₁ smaller than that of the inner beam diameter. In certain such embodiments, the second width KW₂ is between 10% and 50% smaller than the second kerf width KW₂. As one exemplary embodiment, the first kerf width KW₁ is less than 15 μm while the second kerf width KW₂ is 6 μm to 10 μm.

FIG. 3A is a graph of irradiance over time for an iterative laser scribing process, in accordance with an embodiment of the present invention. As shown, irradiance (W/cm²) curve 305 is plotted for a particular point on the substrate along the ablation path. Beginning at time t₀, the point is exposed to radiation having a first irradiance I₁ for the duration of a leading portion 315. At time t₁, irradiation of the radiation increases above a threshold T, for example the threshold energy of a single crystalline substrate material, T_(Si), where the ablation rate begins to increase substantially, which might generally be in the range of 0.01 GW/cm² and 1 GW/cm². Beginning at time t₁, the point is exposed to radiation having a second irradiance I₂ for the duration of a trailing portion 310, ending at time t₂. For the exemplary embodiment, the second irradiance I₂ is above the threshold energy of a single crystalline substrate material, T_(Si). In alternate embodiments, the threshold between I₁ and I₂ is demarked by a threshold associated for any of the mask material (generally in the range of 0.0001 GW/cm² and 0.001 GW/cm²), dielectric layer of the thin film device layer stack 401 (generally in the range of 0.1 GW/cm² and 10 GW/cm²), or an interconnect layer of the thin film device layer stack 401 (generally be in the range of 0.01 G W/cm² and 0.1 GW/cm²).

Iterative ablation (e.g., operations 103 and 104) may be implemented in a number of manners to achieve the change in irradiance illustrated in FIG. 3A. In one embodiment, a laser beam is shaped to have a spatially varying irradiance profile along a direction of travel with the first portion providing the first ablation iteration and second portion providing the second ablation iteration. FIG. 3B is a graph of a spatial profile 320 of an asymmetrically shaped laser beam for a single-pass iterative laser scribing process, in accordance with an embodiment of the present invention. With power (P) plotted along the dimension x, with x increasing along a direction of travel, the spatial profile 320 includes a leading edge portion 315 and a trailing edge portion 310. The leading portion 315 has a lower power (P) than the trailing portion 310 to provide a first irradiance I₁ spanning the distance x₁ to x₂ while a second irradiance I₂ spans the distance x₀ to x₁. With x₀ to x₂ representing the beam width along the direction of travel (whether measured by D4σ, 10/90 knife-edge, 1/e2, FWHM, etc.) for a given width perpendicular to the direction of travel (i.e., y), in the exemplary embodiment illustrated, the trailing edge portion 310 is off-center within the beam width along the direction of travel (i.e., asymmetrical). As further shown in FIG. 3B, at x₁, power exceeds the threshold energy associated with a silicon substrate T_(Si) such that the leading portion 315 does not have sufficient energy to ablate the entire thin film device layer stack 401 while the trailing portion 310 does have sufficient energy to ablate the entire thin film device layer stack 401 as well as a portion of a silicon substrate.

FIG. 2A is a flow diagram illustrating an iterative laser scribing process 200 using a beam with a profile shaped as shown in FIG. 3B to implement the first iteration (operation 103) and second iteration (operation 104) in the method 100 (FIG. 1) with a single beam and a single pass. Referring to FIG. 2A, a single beam is generated at operation 201. In an embodiment, the beam has a pulse width (duration) in the femtosecond range (i.e., 10⁻¹⁵ seconds), referred to herein as a femtosecond laser. Laser parameters selection, such as pulse width, may be critical to developing a successful laser scribing and dicing process that minimizes chipping, microcracks and delamination in order to achieve clean laser scribe cuts. A laser pulse width in the femtosecond range advantageously mitigates heat damage issues relative to longer pulse widths (e.g., picosecond or nanosecond). Although not bound by theory, as currently understood a femtosecond energy source avoids low energy recoupling mechanisms present for picosecond sources and provides for greater thermal nonequilibrium than does a nanosecond-source. With nanosecond or picoseconds laser sources, the various thin film device layer materials present in the street 427 behave quite differently in terms of optical absorption and ablation mechanisms. For example, dielectrics layers such as silicon dioxide, is essentially transparent to all commercially available laser wavelengths under normal conditions. By contrast, metals, organics (e.g., low-K materials) and silicon can couple photons very easily, particularly nanosecond-based or picosecond-based laser irradiation. If non-optimal laser parameters are selected, in a stacked structures that involve two or more of an inorganic dielectric, an organic dielectric, a semiconductor, or a metal, laser irradiation of the street 427 may disadvantageously cause delamination. For example, a laser penetrating through high bandgap energy dielectrics (such as silicon dioxide with an approximately of 9 eV bandgap) without measurable absorption may be absorbed in an underlying metal or silicon layer, causing significant vaporization of the metal or silicon layers. The vaporization may generate high pressures potentially causing severe interlayer delamination and microcracking. Femtosecond-based laser irradiation processes have been demonstrated to avoid or mitigate such microcracking or delamination of such material stacks.

In an embodiment, the laser source for operation 201 has a pulse repetition rate approximately in the range of 200 kHz to 10 MHz, although preferably approximately in the range of 500 kHz to 5 MHz. The laser emission generated at operation 201 may span any combination of the visible spectrum, the ultra-violet (UV), and/or infra-red (IR) spectrums for a broad or narrow band optical emission spectrum. Even for femtosecond laser ablation, certain wavelengths may provide better performance than others depending on the materials to be ablated. In a specific embodiment, a femtosecond laser suitable for semiconductor substrate or substrate scribing is based on a laser having a wavelength of approximately less than or equal to 1570-200 nanometers, although preferably in the range of 540 nanometers to 250 nanometers. In a particular embodiment, pulse widths are less than or equal to 400 femtoseconds for a laser having a wavelength less than or equal to 540 nanometers. In an alternative embodiments, dual laser wavelengths (e.g., a combination of an IR laser and a UV laser) are used to generate the beam at operation 201. In an embodiment, the laser source delivers pulse energy at the work surface approximately in the range of 0.5 μJ to 100 μJ, although preferably approximately in the range of 1 μJ to 5 μJ.

At operation 205, the generated beam is shaped to vary an optical intensity (irradiance) spatial profile as exemplified by FIG. 3B. Any technique known in the art for providing asymmetric spatial profile may be applied at operation 205. For example, known beam shaping optics may be utilized to generate an elliptical beam with the major axis along the direction of travel. In an embodiment, the elliptical beam has a major axis which is at least 1.5 times longer the minor beam axis. Alternatively, coma may be purposefully introduced in order to create a spatial profile as described in FIG. 3A-3C. Additional known beam shaping techniques may be applied at operation 205 along with known generation techniques at operation 201 to provide the change in intensity, or irradiance, between a leading and trailing portions of the elliptical beam's major axis to provide the asymmetrical profile illustrated in FIG. 3B.

At operations 210 and 215, the spatially shaped beam is controlled to travel a predetermined path relative to the substrate to ablate a point on the mask 402 first with the leading portion of the beam (e.g., as illustrated in FIG. 4B) and to subsequently ablate any underlying thin film device stack disposed over the substrate at that point with the trailing portion of the beam (e.g., as illustrated in FIG. 4C). In an embodiment, the laser scribing process runs along a work piece surface in the direction of travel at a speed approximately in the range of 200 mm/sec to 5 msec, although preferably approximately in the range of 300 mm/sec to 2 msec. At operation 220, method 200 returns to FIG. 1 for plasma etch of the exposed substrate.

FIG. 3C is a graph of a spatial profiles 330 and 340 to implement the operations 103 104 in the method 100 (FIG. 1) in a multi-pass embodiment of the present invention. As shown in FIG. 3C, a plurality of beams are provided, each with a different spatial profile. A first profile along a beam width W has a Gaussian 330 or top hat 335 shape with a maximum power (P) below a threshold energy (e.g., T_(Si) in reference to an ablation energy threshold of silicon substrate) while a second beam profile along that same width W has a Gaussian 340 or top hat 345 shape with a maximum power (P) above that threshold energy. As further illustrated in FIG. 3C, the spatial profile 340, 345 associated with the higher irradiance has a power which exceeds the threshold energy (T_(Si)) over a width W₂ which is less than an equivalently determined width W₁ for the spatial profile 330, 335 associated with the lower irradiance.

FIG. 2B is a flow diagram illustrating a laser scribing method 250 using a plurality of beam profiles shaped as shown in FIG. 3C to implement the first iteration (operation 103) and second iteration (operation 104) in the method 100 (FIG. 1) with multiple passes of a single beam. Referring to FIG. 2B, a single beam is generated at operation 225 to have a first irradiance. The beam generation may proceed substantially as previously described for operation 201, for example employing the same femtosecond pulse widths, wavelengths, pulse rates, etc, a beam with a first irradiance I₁, (e.g., Gaussian 330 from FIG. 3C) is generated. At operation 230 the beam is moved along a predetermined path to ablate trenches into the mask, substantially as illustrated in FIG. 4B. In an embodiment, the laser scribing operation 230 runs along a work piece surface in the direction of travel at a speed approximately in the range of 500 mm/sec to 5 msec, although preferably approximately in the range of 600 mm/sec to 2 msec.

At operation 240, the beam is adjusted to have the second irradiance, I₂, (e.g., Gaussian 340 from FIG. 3C) is generated. The adjusted beam retraces the same predetermined path to expose the substrate at operation 245 substantially as illustrated in FIG. 4C at substantially the same rate as for operation 240. At operation 249, method 250 returns to FIG. 1 for subsequent plasma etch of the exposed substrate.

FIG. 2C is a flow diagram illustrating an iterative laser scribing process 290 using a plurality of beam profiles shaped as shown in FIG. 3C to implement the first iteration (operation 103) and second iteration (operation 104) in the method 100 (FIG. 1) with successive passes of beams from a plurality of lasers. Referring to FIG. 2C, a first laser generates a beam with a first irradiance I₁ (e.g., Gaussian 330 from FIG. 3B) is generated at operation 255. The beam generation may proceed substantially as previously described for operation 201, for example employing the same femtosecond pulse widths, wavelengths, pulse rates, etc. In a preferred embodiment however, the laser utilized at operation 255 has a substantially larger pulse width and may even be a continuous wave (CW) source because of the relative ease by which the trenches may be ablated into a masking material. At operation 260, the first beam is moved along a predetermined path to ablate trenches into the mask, substantially as illustrated in FIG. 4B.

At operation 265, a second laser generates a second beam with a second irradiance. Generation of the second beam with the second irradiance I₂ (e.g., Gaussian 335 from FIG. 3B) may proceed substantially as previously described for operation 201, for example employing the same femtosecond pulse widths, wavelengths, pulse rates, etc. In a particular embodiment, where the first laser generates a first pulse train having a first pulse width (CW) at a first wavelength, the second laser generates a second pulse train having a second pulse width and a second wavelength, with at least one of the second pulse width and second wavelength being different than the first pulse width and first wavelength. For example, in the exemplary embodiment where a CW laser is utilized at scribing operation 260, a femtosecond laser generates the second beam at operation 265.

At operation 270 the second laser beam is moved along the same predetermined path to completely ablate the thin film device stack and expose the substrate, substantially as illustrated in FIG. 4C. In an embodiment, the laser scribing operation 270 has both laser beams running along the substrate simultaneously, each with speed in the direction of travel being approximately in the range of 500 mm/sec to 5 msec, although preferably approximately in the range of 600 mm/sec to 2 msec. At operation 275, method 290 returns to FIG. 1 for plasma etch of the exposed substrate.

Returning to FIGS. 1 and 4D, the substrate 406 is exposed to a plasma 416 to etch through the trenches 414 in the mask 402 to singulate the ICs 426 at operation 105. In the exemplary in-situ mask deposition embodiment, the substrate is etched in the same chamber that performed the plasma mask deposition operation 102. In accordance with an embodiment of the present invention, etching the substrate 406 at operation 105 includes etching the trenches 414B formed with the laser scribing process to ultimately etch entirely through substrate 406, as depicted in FIG. 4D.

In one embodiment, the etch operation 105 entails a through via etch process. For example, in a specific embodiment, the etch rate of the material of substrate 406 is greater than 25 μms per minute. A high-density plasma source operating at high powers may be used for the plasma etching operation 105. Exemplary powers range between 3 kW and 6 kW, or more.

In an exemplary embodiment, a deep silicon etch (i.e., such as a through silicon via (TSV) etch) is used to etch a single crystalline silicon substrate or substrate 406 at an etch rate greater than approximately 40% of conventional silicon etch rates while maintaining essentially precise profile control and virtually scallop-free sidewalls. Effects of the high power on any water soluble material layer present in the mask 402 are controlled through application of cooling power via an electrostatic chuck (ESC) chilled to −10° C. to −15° C. to maintain the water soluble mask material layer at a temperature below 100° C. and preferably between 70° C. and 80° C. throughout the duration of the plasma etch process. At such temperatures, water solubility is advantageously maintained.

In a specific embodiment, the plasma etch operation 105 further entails a plurality of protective polymer deposition cycles interleaved over time with a plurality of etch cycles. The duty cycle may vary with the exemplary duty cycle being approximately 1:1-1:2 (etch:dep). For example, the etch process may have a deposition cycle with a duration of 250 msec-750 msec and an etch cycle of 250 msec-750 msec. Between the deposition and etch cycles, an etching process chemistry, employing for example SF₆ for the exemplary silicon etch embodiment, is alternated with a deposition process chemistry employing a polymerizing fluorocarbon (C_(x)F_(y)) gas such as, but not limited to, C₄F₆ or C₄F₈ or fluorinated hydrocarbon (CH_(x)F_(y) with x>=1), or XeF₂. Process pressures may further be alternated between etch and deposition cycles to favor each in the particular cycle, as known in the art.

At operation 107, method 300 is completed with removal of the mask 402. In an embodiment, a water soluble mask layer is washed off with water, for example with a pressurized jet of de-ionized water or through submergence in an ambient or heated water bath. In alternative embodiments, the mask 402 may be washed off with aqueous solvent solutions known in the art to be effective for etch polymer removal. Either of the plasma singulation operation 105 or mask removal process at operation 107 may further pattern the die attach film 408, exposing the top portion of the backing tape 410.

A single integrated process tool 600 may be configured to perform many or all of the operations in the hybrid laser ablation-plasma etch singulation process 100. For example, FIG. 6 illustrates a block diagram of a cluster tool 606 coupled with laser scribe apparatus 610 for laser and plasma dicing of substrates, in accordance with an embodiment of the present invention. Referring to FIG. 6, the cluster tool 606 is coupled to a factory interface 602 (FI) having a plurality of load locks 604. The factory interface 602 may be a suitable atmospheric port to interface between an outside manufacturing facility with laser scribe apparatus 610 and cluster tool 606. The factory interface 602 may include robots with arms or blades for transferring substrates (or carriers thereof) from storage units (such as front opening unified pods) into either cluster tool 606 or laser scribe apparatus 610, or both.

A laser scribe apparatus 610 is also coupled to the FI 602. FIG. 6B illustrates an exemplary functional block diagram of the laser scribe apparatus 610. In an embodiment illustrated in FIG. 6B, the laser scribe apparatus 610 includes a femtosecond laser 665. The femtosecond laser 665 is to performing the laser ablation portion of the hybrid laser and etch singulation process 100. Relative motion between a laser beam and substrate to generate a scribe line can be realized either by moving the laser beam spot, by moving the substrate, or a combination of both. In one embodiment, a moveable stage (not depicted) for supporting the substrate 406 is also included in laser scribe apparatus 610, the moveable stage is configured for moving the substrate 406 (or a carrier thereof) relative to the femtosecond laser 665. As further illustrated, the laser scribe apparatus includes a scanner 670 (e.g., galvanometer) with a mirror movable to scan the laser beam in response to control signals from the controller 680. Between the femtosecond laser 665 and scanner 670 are beam shaping optics 660 which in one embodiment provide an asymmetrically shaped beam profile substantially as shown in FIG. 3B to perform the iterative laser scribing process 200. In further embodiments, the controller 680 is coupled to the femtosecond laser 665 to modulate irradiance of the femtosecond laser 665 across a plurality of non-zero irradiances over time, substantially as illustrated in FIG. 3A, and/or over space substantially as illustrated in FIG. 3C to perform the scribing method 250. In another embodiment, the laser scribe apparatus 610 further includes a second laser 666 which may be femtosecond or otherwise. The second laser 666 is coupled to the controller 680 and each of the lasers 665 and 666 are operated through the scanner 670 successively in time, or simultaneously through separate scanners (i.e., scanner 670 is replicated for completely separate optical paths between the substrate 406 and the lasers), with the controller 680 to direct iterative ablation over substantially the same path to perform the scribing process 290.

Returning to FIG. 6A, the cluster tool 606 includes one or more plasma etch chambers 608 coupled to the FI by a robotic transfer chamber 650 housing a robotic arm for in-vaccuo transfer of substrates between the laser scribe apparatus 610, plasma etch chamber 608 and/or mask module 612. The plasma etch chambers 608 is suitable for at least the plasma etch portion of the hybrid laser and etch singulation process 100 and may further deposit a polymer mask over the substrate. In one exemplary embodiment, the plasma etch chamber 608 is further coupled to an SF₆ gas source and at least one of a C₄F₈, C₄F₆, or CH₂F₂ source. In a specific embodiment, the one or more plasma etch chambers 608 is an Applied Centura® Silvia™ Etch system, available from Applied Materials of Sunnyvale, Calif., USA, although other suitable etch systems are also available commercially. The Applied Centura® Silvia™ Etch system provides capacitive and inductive RF coupling for independent control of the ion density and ion energy than possible with capacitive coupling only, even with the improvements provided by magnetic enhancement. This enables one to effectively decouple the ion density from ion energy, so as to achieve relatively high density plasmas without the high, potentially damaging, DC bias levels, even at very low pressures (e.g., 5-10 mTorr). This results in an exceptionally wide process window. However, any plasma etch chamber capable of etching silicon may be used. In an embodiment, more than one plasma etch chamber 608 is included in the cluster tool 606 portion of the single integrated process tool 600 to enable high manufacturing throughput of the singulation or dicing process.

The cluster tool 606 may include other chambers suitable for performing functions in the hybrid laser ablation-plasma etch singulation process 100. In the exemplary embodiment illustrated in FIG. 6, a mask module 612 includes any commercially available spin coating module for application of the water soluble mask layer described herein. The spin coating module may include a rotatable chuck adapted to clamp by vacuum, or otherwise, a thinned substrate mounted on a carrier such as backing tape mounted on a frame.

FIG. 7 illustrates a computer system 700 within which a set of instructions, for causing the machine to execute one or more of the scribing methods discussed herein may be executed. The exemplary computer system 700 includes a processor 702, a main memory 704 (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory 706 (e.g., flash memory, static random access memory (SRAM), etc.), and a secondary memory 718 (e.g., a data storage device), which communicate with each other via a bus 730.

Processor 702 represents one or more general-purpose processing devices such as a microprocessor, central processing unit, or the like. More particularly, the processor 702 may be a complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, etc. Processor 702 may also be one or more special-purpose processing devices such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. Processor 702 is configured to execute the processing logic 726 for performing the operations and steps discussed herein.

The computer system 700 may further include a network interface device 708. The computer system 700 also may include a video display unit 710 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 712 (e.g., a keyboard), a cursor control device 714 (e.g., a mouse), and a signal generation device 716 (e.g., a speaker).

The secondary memory 718 may include a machine-accessible storage medium (or more specifically a computer-readable storage medium) 731 on which is stored one or more sets of instructions (e.g., software 722) embodying any one or more of the methodologies or functions described herein. The software 722 may also reside, completely or at least partially, within the main memory 704 and/or within the processor 702 during execution thereof by the computer system 700, the main memory 704 and the processor 702 also constituting machine-readable storage media. The software 722 may further be transmitted or received over a network 720 via the network interface device 708.

The machine-accessible storage medium 731 may also be used to store pattern recognition algorithms, artifact shape data, artifact positional data, or particle sparkle data. While the machine-accessible storage medium 731 is shown in an exemplary embodiment to be a single medium, the term “machine-readable storage medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable storage medium” shall also be taken to include any medium that is capable of storing or encoding a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present invention. The term “machine-readable storage medium” shall accordingly be taken to include, but not be limited to, solid-state memories, and optical and magnetic media.

It has been found that while is feasible to keep laser beam irradiance (or fluence assuming a fixed pulse width) at fixed moderate level for multiple passes to generate clean etch trenches, the range of laser power (or pulse energy) levels associated with the optimized fluence level is narrow. This has the practical effect of rendering the laser scribing process window relatively small. It has also been found that a fixed high fluence for multiple passes produces a relatively poor trench topology currently thought to be attributable to a second laser pass redepositing ablated materials onto the trench formed by a first pass.

While a clean trench can be formed with a multiple pass scribing process where a low fluence is employed in the first pass to remove only mask and polyimide layers with limited damage/ablation of an underlying thin film IC layer (more particularly a dielectric layer), and the a high fluence is subsequently employed to remove the device layers to expose the substrate (as in the method 100 illustrated in FIG. 1), delamination may occur. Additional high fluence passes may not always repair or remove such delamination. Though not bound by theory, it is currently thought that in a “low-fluence first” multi-step scribing process, a portion of laser energy in the first pass transmits through the dielectric materials and causes melting/evaporation of metals in the device layer or substrate crystal (e.g., silicon) interfacing with the dielectric layer(s). At low fluence level, ablation of polymers relies primarily on linear absorption of laser energy. Because many polymer masking and passivation materials have a high light transmission ratio (a few tens percent) even for 300 nm UV wavelengths while the ablation threshold of some metals and some substrates (e.g., silicon) is very close to that of many polymers, laser photons transmitted through the dielectric layer(s) of a thin film devices stack may cause delamination at a dielectric-metal and/or dielectric-substrate interface

In certain embodiments therefore, the scribing method includes a first (second, third, etc.) pass at a high irradiance (fluence) level to ablate and remove the materials in the trench to expose the substrate and then a second (third, fourth, etc.) pass at a low irradiance (fluence) level to remove debris and residues left over in the ablated trench without significant damage to the substrate. This type of “high-fluence-first” process may render a clean exposed substrate surface with a wider process window than either a fixed fluence multiple pass process or a low-fluence-first process. As mask or polymeric passivation layers get thicker relative to the scribe trench width (e.g., width is reduced or layer thickness is increased), a high-fluence-first approach becomes more advantageous.

FIG. 8A is a flow diagram illustrating a hybrid laser ablation-plasma etch singulation method 801 in which a laser scribing process leads with a first irradiance and follows with a second irradiance that is lower than the first irradiance, in accordance with an embodiment of the present invention. Method 801 begins with a masked substrate at operation 101, as described elsewhere herein. An exemplary substrate is illustrated by the cross-sectional view in FIG. 4A.

At operation 255, a first beam having the first irradiance is generated at operation 255. The beam is generated in any of the manners described elsewhere herein. In one embodiment, a laser having a predetermined pulse width, such as the femtosecond pulse widths described elsewhere herein, is operated at a first fluence level no less than 1.0 μJ, and preferably 1.5 μJ or higher for a 10 μm diameter spot size to achieve the first irradiance. This fluence level range is sufficient to ablate dielectric layers of the thin film IC stack (e.g., layers 504 and 507 in FIG. 5). In one femtosecond laser beam embodiment with a focused spot diameter of 10 μm, pulse width in the range of 300 fs to 1.5 ps, a laser wavelength in the range of 1570 nm to 300 nm, the high fluence level was determined to correspond to a pulse energy level of 1.5 μJ or more.

At operation 860, a beam from the laser operating at the first fluence level moves along a predetermined path to ablate trenches through the masking material, IC passivation, and thin film device layers to expose the substrate. FIGS. 8B, 8C, and 8D illustrate cross-sectional views of a substrate, such as that illustrated in FIG. 4A, as operations of the dicing method illustrated in FIG. 8A are performed, in accordance with an embodiment of the present invention.

FIG. 8B, the first pass of the laser operated at the first fluence level at operation 860 ablates the trench 814A exposing the substrate 406 along a first kerf width (KW₁). In the exemplary embodiment, the first fluence is sufficient to ablate every layer of the thin film device layer stack 401 and therefore operation 103 leaves the substrate 406 exposed at the bottom of the trench 414A. The kerf width KW₁ is a function of a beam width possessing an intensity I₁ greater than a threshold associated for the particular materials in the thin film device layer stack 401, particularly the dielectric layer threshold (T_(D)), as discussed above. For this reason, the mask 402, having a lower threshold may have a kerf width (KW_(M)) which is wider than kerf width KW₁. As further shown in FIG. 8B, the operation 860 leaves splats of residue 802 at the bottom of the trench 814A, which includes redeposited materials from the mask and IC passivation (e.g., organics). Metals and dielectrics from the thin film device layer stack 401 may also be incorporated with mask and passivation material in the residue 802.

Returning to FIG. 8A, at operation 860 a second laser beam is generated having a second irradiance that is lower than the first irradiance. Where the same pulse width is employed (e.g., femtosecond), the reduction in irradiance may be achieved with a reduction in fluence. In particular femtosecond embodiments, the fluence at operation 860 is no greater than 1 μJ for a 10 μm diameter spot size, and preferably 0.75 μJ, or less. This fluence level range is insufficient to ablate dielectric layers of the thin film IC stack (e.g., layers 504 and 507 in FIG. 5). In one particular embodiment with a focused spot diameter of 10 μm, pulse width in the range of 300 fs to 1.5 ps, and laser wavelength in the range of 1570 nm to 300 nm, a low fluence level was determined to be 0.75 μJ, or less.

At operation 870, a beam from the laser operating at the second fluence level moves along the same predetermined path followed at operation 860 to ablate trenches through the masking material, IC passivation, and thin film device layers to remove the spats of residue 802 left by the operation 860. As further illustrated in FIG. 8C, the radiation 411 has a second intensity I₂ less than that of I₁ (shown in dashed line as illustration of the difference between I₁ an I₂). As illustrated, because the second fluence level does not exceed the dielectric layer threshold (TD), there is no additional direct ablation of the dielectric layers and the kerf width KW₁ through thin film device stack 401 does not change significantly. However, because the thresholds associated with polymer materials typical for the mask and passivation are low, the second fluence level (irradiance) will remove residues over the entire first kerf width of the trench to provide a cleaner trench bottom 814B.

Returning to FIG. 8A, at operation 105, the plasma etch operation is performed as described elsewhere herein. As further illustrated by FIG. 8C, the plasma etch advances the cleaned trench bottom 814B through the substrate. With the splat residues 802 removed by the lower fluence ablation, the plasma etched trench has substantially the same kerf width (KW₁) as provided by the high fluence ablation. At operation 107 (FIG. 8A) the mask may then be removed, as described elsewhere herein.

It should be noted that high-fluence-first embodiments exemplified by method 801 may be implemented with any of the techniques and hardware described elsewhere herein in terms of an exemplary low-fluence-first process. For example, in one embodiment the iterative ablating operations 860 and 870 may be performed with multiple passes with a same laser operating at different fluence levels or with multiple lasers performing one or more pass. Similarly, beam shaping techniques may be performed to vary the spatial profile of the beam. For example, direction of travel may be reversed from that shown in FIG. 3B to affect a high-fluence-first process rather than a low-fluence-first process. Similarly, all the hardware illustrated in FIGS. 6A, 6B and 7 described in the context of a low-fluence-first embodiments (i.e. low-irradiance first process where pulse width is fixed) may be operated in substantially the same manner to implement high-fluence-first embodiments.

As an alternative to the multi-step method 801 which either involves a power re-adjustment or a second laser for the second pass (operations 265 and 870), higher throughput may be achieve with the multi-step method 901 illustrated in FIG. 9A which employs a beam splitter. The exemplary embodiment illustrated in FIG. 9A begins with a receipt of a mask substrate at operation 101 and generation of a beam at operation 201, as described elsewhere herein. At operation 965, the beam is split into leading and trailing beams of the different irradiance (fluence) levels, I₁, I₂ with I₁ and I₂ having the relative levels of any embodiment described elsewhere herein. At operation 970, the split beams are displaced in unison relative to the substrate along a predetermined path in any of the manners described herein. Depending on the direction of relative displacement between the substrate in relation to relative power of the split beam spots, a high-fluence-first or high-fluence-last iterative scribing method may be implemented with a single pass. In the exemplary embodiment, the split beam method 901 implements a high-fluence-first scribing method. Method 901 completes die singulation with the plasma etch and mask removal operations 105 and 107, as previously described.

Any commercially available variable beam splitter may be utilized for operation 965. For example, in one embodiment a coated disk of glass in which the reflectivity of the coating varies angularly, so that on rotating the disk one can select the desired power ratio between two beams produced by the device. In a further embodiment, a diffractive optical element (DOE) is employed where a phase grating concentrates most of the laser energy on two diffraction orders. In an embodiment where a diffractive beam splitter is used to duplicate a master beam into multiple replica beams having diameters equal to that of the input beam and positioned in a one- or two-dimensional array at well-specified angles, the phase profile of the beam generated at operation 201 is chosen so that the power ratio between the diffraction orders has a prescribed value. In further embodiments, different power ratios between produced replicas may be chosen on adjacent diffracting elements of the grating. Accordingly, a lateral shift in position of the DOE selects the desired value of the power ratio between the multiple beam replicas used to implement split beam method 901.

FIG. 9B illustrates a schematic diagram of a laser scribing module 900 for split beam laser scribing, in accordance with an embodiment of the present invention. In FIG. 9B, the laser 902 provides the beam to a beam expander and collimator 904. In one embodiment, the laser 902 is operated at or close to the maximum pulse repetition rate which will deliver a required pulse energy at each foci of a M×N dot matrix. Optionally, the beam may be passed through a Gaussian to top-hat beam shaping module 906, however such profile conversion will typically lose at least 30% of the incoming power, which may not be acceptable for femtosecond embodiments in which power is already relatively low compared to picosecond sources, for example. The resulting beam, either from beam expander and collimator 904 or from the Gaussian to top-hat beam shaping module 906, or both, is passed through variable beam splitting module 908 with the split beams then passing through a telecentric lens 910 for transmission onto a substrate 912 so that the focused spot-to-spot distance equals to the required die size for scribing in at least one dimension.

As illustrated by the B-B view of the beam spot pattern in FIG. 9B, the beam is split into leading and trailing beams of the different irradiance (fluence) levels, I₁, I₂ with I₁ and I₂ having the relative levels of any embodiment described elsewhere herein. Depending on the direction of relative displacement between the substrate 912 in relation to relative power of the split beam spots illustrated in the B-B view of FIG. 9B, a high-fluence-first or high-fluence-last iterative scribing method may be implemented with a single pass. In the exemplary embodiment shown in FIG. 9B, the illustrated scribing direction implements the high-fluence-first scribing method. Although shown as square patterns in FIG. 9B, it is to be understood that the A-A view and B-B view may also be rectangular in pattern, etc.

FIG. 10 further illustrates a diffractive beam splitting apparatus 1000, in accordance with an embodiment of the present invention. An incident laser 1002 passes through the diffractive optical element (DOE) 1004 with a focusing lens 1006 having multiple foci provides multiple beams, points or spots to a working area 1008. In one embodiment, the focusing lens 1006 is telecentric to ensure the incident beam point is delivered perpendicularly onto a work surface since there may exist a non-zero split angle subsequent to splitting the laser beam through, e.g., a diffractive beam splitter. In one such embodiment, a telecentric focal lens of appropriate focal length is employed to provide N×N beams with a pitch in one dimension equal to d, a pitch of streets between a plurality of ICs.

Thus, methods of dicing semiconductor substrates, each substrate having a plurality of ICs, have been disclosed. The above description of illustrative embodiments of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific implementations of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. The scope of the invention is therefore to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation. 

What is claimed is:
 1. A method of dicing a substrate comprising a plurality of ICs, the method comprising: receiving the substrate with an unpatterned polymeric mask covering and protecting the ICs; ablating with a laser a predetermined pattern of trenches into the mask and into a thin film IC stack disposed below the mask to expose a portion of a substrate, the ablating leading with electromagnetic radiation having a first irradiance and following with electromagnetic radiation having a second irradiance, lower than the first, wherein the first irradiance is sufficient to ablate a non-polymeric layer of the thin film IC stack under the mask and wherein the second irradiance is insufficient to ablate the non-polymeric layer; and plasma etching the through substrate exposed by the patterned mask trenches to singulate the ICs.
 2. The method of claim 1, wherein the electromagnetic radiation is from a single laser having a predetermined pulse width, the first irradiance associated with a first pass of the laser operated at a first fluence that is higher than a second fluence associated with the second irradiance.
 3. The method of claim 2, wherein the first fluence is greater than 1.0 μJ for a 10 μm diameter spot size and wherein the second fluence is less than 1.0 μJ for a 10 μm diameter spot size, with a pulse width between 300 fs and 1.5 ps.
 4. The method of claim 1, wherein the electromagnetic radiation with the first irradiance forms a trench in the mask having a first kerf width and wherein the electromagnetic radiation with the second irradiance removes residues within the first kerf width of the trench.
 5. The method of claim 1, wherein the ablating further comprises ablating the unpatterned mask, wherein the mask is a water-soluble polymer, a polymeric passivation layer disposed below the unpatterned mask, and the thin film device stack including a dielectric layer with the radiation having the first irradiance, and ablating redeposited polymeric mask or passivation material with the radiation having the second irradiance that is insufficient to ablate the dielectric layer.
 6. The method of claim 2, wherein the ablating comprises a laser having a wavelength less than or equal to 540 nanometers and a pulse width less than or equal to 400 femtoseconds.
 7. The method of claim 1, wherein the ablating comprises splitting a beam from the laser into an array of beams, wherein a first beam of the array has the first irradiance and a second beam of the array has the second irradiance.
 8. The method of claim 7, wherein the array of beams is two dimensional with pitch of the beams in at least one dimension equal to a pitch of streets separating adjacent ones of the plurality of ICs.
 9. The method of claim 1, wherein the substrate is silicon and the plasma etching comprises an anisotropic deep silicon etch process employing a cyclic etch and polymer deposition process.
 10. A method of dicing a substrate comprising a plurality of ICs, the method comprising: receiving the substrate with an unpatterned mask covering and protecting the ICs; ablating with a laser a predetermined pattern of trenches into the mask and into a thin film IC stack disposed below the mask to expose a portion of a substrate, the ablating leading with electromagnetic radiation having a first irradiance and following with electromagnetic radiation having a second irradiance, lower than the first, and wherein the ablating comprises splitting a beam from the laser into an array of beams, wherein a first beam of the array has the first irradiance and a second beam of the array has the second irradiance; and plasma etching the through substrate exposed by the patterned mask trenches to singulate the ICs.
 11. The method of claim 10, wherein the first irradiance is associated with a first fluence greater than 1.0 μJ for a 10 μm diameter spot size and wherein the second irradiance is associated with a second fluence that is less than 1.0 μJ for a 10 μm diameter spot size, with a pulse width between 300 fs and 1.5 ps.
 12. The method of claim 10, wherein the ablating comprises a laser having a wavelength less than or equal to 540 nanometers and a pulse width less than or equal to 400 femto seconds.
 13. The method of claim 7, wherein the array of beams is two dimensional with pitch of the beams in at least one dimension equal to a pitch of streets separating adjacent ones of the plurality of ICs. 